Starting to think ol' Barbara has it out for me. That and a dose of me being a bit of a numpty. Had a few weird adventures lately.
Both the alternator ducts were missing when I got the car so I found an upper one on one of my parts cars, ordered a new lower one and fitted them on once I got the car up and running. Fast forward about a week and found the lower one rattling around on the undertray. The fittings on it are a bit flimsy so it must have vibrated itself loose, jammed itself against the belt and chewed through it. Luckily doesn't look to have done any damage to the belts or pulleys.
Last Friday was going about my business, filled the tank on my way to Supercheap to pick up some oil. Pull up to the parking lot and felt a strong whiff of petrol. Looked down to find a massive puddle of fuel spewing out from the bottom of the car. Either I didn't seat the seal properly / didn't tighten the fuel pump lock ring enough or just because I overfilled the tank but the fuel was overflowing through the seal on the pump side. Quickly got the staff to help, grabbed the spill kit to clean it up as it looked a fire hazard.
Video 1
Video 2
Undid the fuel pump to find the tank up to the brim and overflowing. Luckily I was already at the store so bought a siphon and a fuel cannister and pumped a few litres out. Seated the seal properly this time and tightened down the lock ring as far as it wanted to go. Looks fine now but will take a wee while to air out the smell of fuel from the cabin.
Still have a persistent rattle from the engine for the first second or two on a cold start. At that point I'd done 500km on the special 15W-40 running in oil so figured it must be time to switch to the usual Castrol Edge 5W-30. Way less metallic sludge stuck to the magnetic drain plug than after the first 100km, the oil looked nice and clear still but the fresh 5W-30 didn't fix the ticking either. Not quite sure what it might be still or whether to be too worried about it. Probably worth getting a set of new lifters at some point as the old ones did look a bit tired.
After the oil change, took the car out for its first proper drive today, a small club run to Arthur's Pass. Very nice drive with some nice hilly and twisty bits. Just 8 cars in total with an E46 M3 vert, F30 335i and an X5 outside the picture.
Mine was the only "project car" in the group and of course decided to be the problem child. Just before Sheffield heard a slight thump and the HVAC screen went blank. The fella behind me told me it also blew a black puff of smoke out the exhaust around the same time. Made it to the parking lot to discover the AC compressor had spat the dummy and spewed out some sort of sticky gunk all over.
Out of everything under the hood, the AC was the only thing I hadn't touched so naturally it got jealous and started acting up. The compressor was due a replacement to be fair but didn't want to touch it until the engine was all sorted. Will have to expedite it a bit. Luckily had my toolbox with me (as is a must at this stage) so just took the AC belt off and carried on.
Apart from that, no major dramas. The car ran really well, temperatures kept steady, pulls nice and solid, especially with the auto diff, although taking off from a stand still is still an absolute pain so will switch it out for the manual diff shortly. The alignment is all over the place but holds the road steady enough. Will leave it until I get onto the rear subframe and suspension work. Still keeping it under 4k RPM for a few thousand km's so didn't go too crazy, although did try to keep pace with the E92 M3 to enjoy those V8 noises.
The drive back was a bit of a pain with no AC as the outside temperatures hit 30 degrees. Might look into getting some of those wind deflector things that fit onto the tops of the door frames as the turbulence was unbearable with the windows open. Was absolutely drenched by the time I got home. Getting back into town I nearly got T-boned by an SUV that obliviously started pulling out from a side road right into the side of me which didn't help with the sweating. Luckily managed to swerve out of the way just in time. NZ driving culture man...
But yeah, a few gremlins still but not totally unexpected. Will just keep chipping away.